Redundant installation system of sizing feeding hook low-position sensor and diagnosis control method

Abstract

The invention relates to a redundancy installation system of a sizing feeding hook low-position sensor and a diagnosis control method, the redundancy installation system comprises a mechanical redundancy unit, a sensing redundancy unit, an electrical connection unit and a signal processing and diagnosis unit, the mechanical redundancy unit is used for installing the sensing redundancy unit, the sensing redundancy unit is used for detecting signals, and the electrical connection unit is used for connecting the electrical connection unit with the signal processing and diagnosis unit. The electrical connection unit is used for transmitting signals of the sensing redundancy unit, and the signal processing and diagnosing unit is used for diagnosing according to the signals of the sensing redundancy unit. According to the invention, through mechanical and electrical dual redundancy design, a single point fault is eliminated, and a position detection signal can be ensured to be continuously effective when any single element fails, so that non-planned shutdown caused by the single point fault is avoided; meanwhile, double-path sensor signals can be analyzed in real time, seamless switching under the fault condition is achieved, the fault property can be accurately judged, clear maintenance guidance is given, and the troubleshooting and recovery time is greatly shortened.

Description

Technical Field

[0001] This invention belongs to the field of industrial automation control technology, and in particular to a redundant installation system and diagnostic control method for a low-position sensor of a sizing hook. Background Technology

[0002] In modern hot continuous rolling mill production lines, the sizing process is a crucial step in ensuring the dimensional accuracy of the final product. The feeding hook, located at the junction of the continuous rolling zone and the sizing zone, plays a vital role in smoothly and accurately transferring the intermediate billets after continuous rolling to the inlet guide of the sizing mill. The timing and positional accuracy of the feeding hook directly affect the continuous operation of the production line, equipment safety, and product quality.

[0003] To ensure absolute safety and prevent major accidents such as equipment collisions and steel pile-up (commonly known as "stick jamming") caused by malfunctions of the sizing mill or continuous rolling mill when the feeding hook has not fully descended to the low receiving position, existing technical standards require the installation of a position sensor (usually a proximity switch) at the low limit position of the feeding hook. The sensor's detection signal is used as one of the core safety interlock conditions and is connected to the main control signal processing and diagnostic unit (programmable logic controller) of the production line. When the sensor detects that the feeding hook is "not in the low position," the control system will immediately prohibit continuous rolling or trigger an emergency shutdown. This is a typical "fail-safe" design concept.

[0004] However, existing widely used low-position detection schemes based on a single proximity switch are revealing increasingly serious defects and risks in actual industrial production environments, mainly as follows: (1) The system reliability has a single point of failure bottleneck; (2) The root cause of the fault is difficult to find and the repair is time-consuming; (3) Lack of fault early warning and performance degradation monitoring capabilities; (4) The existing installation structure is not conducive to reliability and maintainability; Therefore, there is an urgent need for a comprehensive solution that integrates high-reliability redundant design, intelligent fault self-diagnosis, maintenance-friendly structure, and energy efficiency management to thoroughly improve the safety level and operating efficiency of the low-position detection system for the loading hook. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and propose a redundant installation system and diagnostic control method for the low-position sensor of the sizing hook. Through the dual redundancy design of mechanical and electrical components, single-point failures are eliminated, ensuring that the position detection signal remains effective even if any single component fails, thereby avoiding unplanned downtime caused by this. At the same time, this invention can analyze the dual-channel sensor signals in real time, not only achieving seamless switching in fault conditions, but also accurately judging the nature of the fault and providing clear maintenance guidance, greatly shortening the fault diagnosis and recovery time.

[0006] The technical problem solved by this invention is achieved through the following technical solution: The redundant installation system for the low-position sensor of the sizing hook includes a mechanical redundancy unit, a sensing redundancy unit, an electrical connection unit, and a signal processing and diagnostic unit. The sensing redundancy unit is connected to the signal processing and diagnostic unit through the electrical connection unit. The mechanical redundancy unit is used to install the sensing redundancy unit, the sensing redundancy unit is used to detect signals, the electrical connection unit is used to transmit signals from the sensing redundancy unit, and the signal processing and diagnostic unit is used to perform diagnostics based on the signals from the sensing redundancy unit.

[0007] Furthermore, the mechanical redundancy unit includes a sensor bracket, which has a first mounting hole and a second mounting hole, and the first mounting hole and the second mounting hole are fixedly arranged side by side and with parallel axes.

[0008] Furthermore, the sensor bracket includes a base and a fixed arm mounted on the base. The fixed arm is provided with a first mounting hole and a second mounting hole, respectively. The line connecting the centers of the first mounting hole and the second mounting hole is parallel to the motion trajectory plane of the feeding hook block.

[0009] Furthermore, the sensing redundancy unit includes a first proximity switch and a second proximity switch respectively fastened to the first mounting hole and the second mounting hole. The sensing surfaces of the first proximity switch and the second proximity switch face the same detection area, and are used to synchronously detect the position of the feeding hook block.

[0010] Furthermore, the electrical connection unit includes a first independent cable and a second independent cable. The first independent cable is connected to the first proximity switch, and the second independent cable is connected to the second proximity switch. Both the first independent cable and the second independent cable have a double-layer shielding structure.

[0011] Furthermore, the input terminal of the signal processing and diagnostic unit is connected to the first independent cable and the second independent cable, and is used to collect, compare and judge the dual signals from the redundant sensing unit in real time, and output the final position status signal, fault alarm signal and diagnostic information.

[0012] A diagnostic control method for a redundant installation system of a low-position sensor for a sizing hook includes the following steps: Step 1: Power on and initialize the system, performing a self-test of the dual sensors and signal channels; Step 2: Real-time synchronous sampling of the first proximity switch signal S1 and the second proximity switch signal S2; Step 3: Based on the logical states of S1 and S2, perform multi-level judgments, including normal operation mode, single sensor fault mode, and mechanical anomaly judgment. Step 4: Perform the action based on the judgment in Step 3.

[0013] Moreover, the specific implementation method of the normal operation mode judgment is as follows: when both the first proximity switch signal S1 and the second proximity switch signal S2 are at an effective level, it is determined that the feeding hook is in the correct low position and a normal low position signal is output. The single-sensor fault mode determination is as follows: when S1 is invalid and S2 is valid, the first proximity switch is determined to be faulty, the first fault alarm signal is output, and the system's valid signal source is automatically switched to S2; conversely, when S2 is invalid and S1 is valid, the second proximity switch is determined to be faulty, the second fault alarm signal is output, and the system's valid signal source is automatically switched to S1. Mechanical abnormality is determined as follows: when both S1 and S2 are invalid, it is determined that the feeding hook stop is not in place or the stop position has mechanically shifted, outputting a mechanical abnormality alarm signal and triggering the equipment safety interlock shutdown.

[0014] The advantages and positive effects of this invention are: This invention eliminates single-point failures through a dual redundancy design of mechanical and electrical components, ensuring that the position detection signal remains effective even if any single component fails, thereby avoiding unplanned downtime. At the same time, this invention can analyze dual-channel sensor signals in real time, not only achieving seamless switching in fault conditions, but also accurately determining the nature of the fault and providing clear maintenance guidance, greatly shortening the time for fault diagnosis and recovery. Attached Figure Description

[0015] Figure 1 This is a structural block diagram of the system of the present invention.

[0016] Figure 2 This is a structural diagram of the system of the present invention; 1-Mechanical redundancy unit, 2-Sensing redundancy unit, 3-Sensing redundancy unit, 4-Signal processing and diagnostic unit, 5-Sensor bracket, 6-Base, 7-Fixed arm, 8-Fixed arm, 9-Second mounting hole, 10-First proximity switch, 11-Second independent cable. Detailed Implementation

[0017] The present invention will be further described in detail below with reference to the accompanying drawings.

[0018] A redundant installation system for the low-position sensor of the sizing hook, such as... Figure 1 As shown, it includes a mechanical redundancy unit 1, a sensor redundancy unit 2, an electrical connection unit 3, and a signal processing and diagnostic unit 4. The sensor redundancy unit is connected to the signal processing and diagnostic unit through the electrical connection unit. The mechanical redundancy unit is used to install the sensor redundancy unit, the sensor redundancy unit is used to detect signals, the electrical connection unit is used to transmit signals from the sensor redundancy unit, and the signal processing and diagnostic unit is used to perform diagnostics based on the signals from the sensor redundancy unit.

[0019] like Figure 2 As shown, the mechanical redundancy unit includes a sensor bracket 5, which has a first mounting hole and a second mounting hole. The first mounting hole and the second mounting hole are fixedly arranged side by side with parallel axes.

[0020] The sensor bracket includes a base 6 and a fixed arm 7 mounted on the base. The fixed arm has a first mounting hole 8 and a second mounting hole 9, respectively. The line connecting the centers of the first and second mounting holes is parallel to the plane of the movement trajectory of the feeding hook stop. The sensor bracket is integrally machined from 316L stainless steel sheet after welding.

[0021] The sensing redundancy unit includes a first proximity switch and a second proximity switch, respectively fastened to the first mounting hole and the second mounting hole. The sensing surfaces of the first and second proximity switches face the same detection area for synchronous detection of the position of the loading hook stop. The first and second proximity switches are Ni20-UH-EO-2M model high-temperature resistant inductive proximity switches. These switches have an M18×1 thread, a detection distance of 20mm, a built-in PPS plastic sensing surface, an operating temperature range of -40℃ to +150℃, and an IP68 protection rating.

[0022] The electrical connection unit includes a first independent cable 10 and a second independent cable 11. The first independent cable connects to a first proximity switch, and the second independent cable connects to a second proximity switch. Both the first and second independent cables have a double-shielded structure. Both the first and second independent cables are made of high-temperature resistant fluoroplastic insulated and fluoroplastic sheathed double-shielded cables with a core cross-section of 1.5 mm². 2 The cable is sheathed in a Φ12mm stainless steel flexible conduit for mechanical protection. One end of the cable connects to the proximity switch via a first high-temperature sealing connector and a second high-temperature sealing connector. After exiting the sensor, the two cables run independently along two pre-installed cable trays / conduits on the equipment body, ultimately connecting to the signal processing and diagnostic unit. Crossing is avoided throughout the entire process, and aluminum silicate refractory fiber blankets are used for insulation in high-temperature areas.

[0023] The input terminal of the signal processing and diagnostic unit is connected to the first independent cable and the second independent cable, and is used to acquire, compare and judge the dual signals from the redundant sensing unit in real time, and output the final position status signal, fault alarm signal and diagnostic information.

[0024] The signal processing and diagnostic unit also includes the following functions: Signal debouncing: Software filtering (such as moving average or hysteresis comparison) is applied to the original input signal to eliminate instantaneous false triggers caused by vibration.

[0025] Fault Locking and Confirmation: When a single sensor fault state (such as (1,0)) is detected, the program will continuously monitor the state for several scan cycles (such as 100ms). Only after confirming that it is a persistent fault rather than a transient interference will an alarm be issued and a switchover be executed to prevent false alarms.

[0026] Timestamp recording: The occurrence time, duration, and type of any fault event (including sensor failure, mechanical abnormality, signal switching) will be accurately recorded in the retention storage area of ​​the signal processing and diagnostic unit or sent to the host computer database for the purpose of generating maintenance reports and statistical analysis.

[0027] A diagnostic control method for a redundant installation system of a low-position sensor for a sizing hook includes the following steps: Step 1: Power on the system and initialize it, performing a self-test of the dual-channel sensors and signal channels.

[0028] Step 2: Real-time synchronous sampling of the first proximity switch signal S1 and the second proximity switch signal S2.

[0029] Step 3: Based on the logic states of S1 and S2, perform multi-level judgments, including normal operation mode, single sensor fault mode, and mechanical anomaly judgment.

[0030] The specific implementation method for determining the normal operation mode is as follows: when both the first proximity switch signal S1 and the second proximity switch signal S2 are at an effective level, it is determined that the feeding hook is in the correct low position and a normal low position signal is output. The single-sensor fault mode determination is as follows: when S1 is invalid and S2 is valid, the first proximity switch is determined to be faulty, the first fault alarm signal is output, and the system's valid signal source is automatically switched to S2; conversely, when S2 is invalid and S1 is valid, the second proximity switch is determined to be faulty, the second fault alarm signal is output, and the system's valid signal source is automatically switched to S1. Mechanical abnormality is determined as follows: when both S1 and S2 are invalid, it is determined that the feeding hook stop is not in place or the stop position has mechanically shifted, outputting a mechanical abnormality alarm signal and triggering the equipment safety interlock shutdown.

[0031] Step 4: Perform the action based on the judgment in Step 3.

[0032] Based on the redundant installation system and diagnostic control method of the low-position sensor of the sizing hook described above, the effectiveness of the present invention was verified by conducting tests.

[0033] Initialization: After power-on, the signal processing and diagnostic unit first performs a self-test to check if the hardware of the two input channels is ready. Then, it reads the initial states of S1 and S2. If the initial state is (0,0), it waits for the loading hook to move once to confirm whether the problem is due to the actual machine not being in place or a sensor installation issue.

[0034] Main loop scan: Step S201: In each OB1 loop (typical cycle 10ms), read S1' and S2' after hardware and software filtering.

[0035] Step S202: Perform a logical judgment based on (S1', S2').

[0036] Step S203: If it is (1,1), then set the "system normal" flag, reset all fault flags, and output the "low bit valid" signal (for example, set an internal flag bit or output point to 1).

[0037] Step S204: If the value is (1,0), start the "Fault A Confirmation Timer". If this state continues for more than T_conf (e.g., 100ms), determine that the first proximity switch 2 is faulty. Set the "Sensor A Fault" alarm bit, trigger the HMI alarm, and record the log. At the same time, forcibly associate the system's "Valid Low-Level Signal" with the S2' channel. Even if S1' recovers afterward, the system will still maintain S2' as the valid signal until manually reset.

[0038] Step S205: If it is (0,1), the processing logic is the same as S204. The second proximity switch 3 is determined to be faulty, and the process is switched to S1'.

[0039] Step S206: If it is (0,0), immediately set the "Mechanical Abnormality" alarm position, trigger the highest level audible and visual alarm, and output a "Low-level Invalid" signal (safety side) to trigger interlock shutdown. At the same time, "Check stop 6 and feeding hook drive mechanism" will be highlighted on the HMI.

[0040] Background feature analysis task: The signal feature analysis program runs in a low-priority but periodically stable cyclic interrupt OB (such as OB35, period 100ms).

[0041] Collect the original high-speed samples of S1 and S2.

[0042] When a signal edge (from 0 to 1 or from 1 to 0) is detected, a precise system timestamp is recorded.

[0043] Calculate the time difference Δt between the edges of S1 and S2. When the system is normal and the stop position is accurate, Δt should be close to 0 (<1ms). Set the threshold ΔT_max = 5ms.

[0044] If |Δt|>ΔT_max is detected multiple times consecutively (e.g., 10 times), and S1 always lags behind S2, it is inferred that the response of the first proximity switch 2 is slow, which may indicate performance degradation. A "Sensor A response delay warning" message is generated on the HMI, and observation is recommended.

[0045] Analyze the stability of the signal in the ON or OFF state, and calculate the number of state transitions (jitter) within a certain time window. If the number of jitters of one sensor is significantly higher than that of another, it indicates that its anti-interference capability has decreased or that its installation is loose.

[0046] It should be emphasized that the embodiments described in this invention are illustrative rather than limiting. Therefore, this invention includes, but is not limited to, the embodiments described in the specific implementation. Any other implementations derived by those skilled in the art based on the technical solutions of this invention are also within the scope of protection of this invention.

Claims

1. A redundant installation system for a low-position sensor of a sizing hook, characterized in that: It includes a mechanical redundancy unit, a sensor redundancy unit, an electrical connection unit, and a signal processing and diagnostic unit. The sensor redundancy unit is connected to the signal processing and diagnostic unit through the electrical connection unit. The mechanical redundancy unit is used to install the sensor redundancy unit, the sensor redundancy unit is used to detect signals, the electrical connection unit is used to transmit signals from the sensor redundancy unit, and the signal processing and diagnostic unit is used to perform diagnostics based on the signals from the sensor redundancy unit.

2. The redundant installation system for the low-position sensor of the sizing hook according to claim 1, characterized in that: The mechanical redundancy unit includes a sensor bracket, which has a first mounting hole and a second mounting hole, and the first mounting hole and the second mounting hole are fixedly arranged side by side and with parallel axes.

3. The redundant installation system for the low-position sensor of the sizing hook according to claim 2, characterized in that: The sensor bracket includes a base and a fixed arm mounted on the base. The fixed arm is provided with a first mounting hole and a second mounting hole, respectively. The line connecting the centers of the first mounting hole and the second mounting hole is parallel to the motion trajectory plane of the feeding hook block.

4. The redundant installation system for the low-position sensor of the sizing hook according to claim 1, characterized in that: The sensing redundancy unit includes a first proximity switch and a second proximity switch, which are respectively fastened to the first mounting hole and the second mounting hole. The sensing surfaces of the first proximity switch and the second proximity switch face the same detection area and are used to synchronously detect the position of the feeding hook block.

5. The redundant installation system for the low-position sensor of the sizing hook according to claim 1, characterized in that: The electrical connection unit includes a first independent cable and a second independent cable. The first independent cable is connected to a first proximity switch, and the second independent cable is connected to the second proximity switch. Both the first independent cable and the second independent cable have a double-layer shielding structure.

6. The redundant installation system for the low-position sensor of the sizing hook according to claim 1, characterized in that: The input terminal of the signal processing and diagnostic unit is connected to the first independent cable and the second independent cable, and is used to collect, compare and judge the dual signals from the redundant sensing unit in real time, and output the final position status signal, fault alarm signal and diagnostic information.

7. A diagnostic control method for a redundant installation system of a low-position sensor for a sizing hook as described in any one of claims 1 to 6, characterized in that: Includes the following steps: Step 1: Power on and initialize the system, performing a self-test of the dual sensors and signal channels; Step 2: Real-time synchronous sampling of the first proximity switch signal S1 and the second proximity switch signal S2; Step 3: Based on the logical states of S1 and S2, perform multi-level judgments, including normal operation mode, single sensor fault mode, and mechanical anomaly judgment. Step 4: Perform the action based on the judgment in Step 3.

8. The diagnostic control method for the redundant installation system of the low-position sensor of the sizing hook according to claim 7, characterized in that: The specific implementation method for determining the normal operating mode is as follows: when both the first proximity switch signal S1 and the second proximity switch signal S2 are at an effective level, it is determined that the feeding hook is in the correct low position and a normal low position signal is output. The single-sensor fault mode determination is as follows: when S1 is invalid and S2 is valid, the first proximity switch is determined to be faulty, the first fault alarm signal is output, and the system's valid signal source is automatically switched to S2; conversely, when S2 is invalid and S1 is valid, the second proximity switch is determined to be faulty, the second fault alarm signal is output, and the system's valid signal source is automatically switched to S1. Mechanical abnormality is determined as follows: when both S1 and S2 are invalid, it is determined that the feeding hook stop is not in place or the stop position has mechanically shifted, outputting a mechanical abnormality alarm signal and triggering the equipment safety interlock shutdown.

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